#Weaving

2023-10-26

Advantages of yarn intermingling for weaving and warp knitting

Carrier with 28 WarpJet-KVs for 1,792 threads © 2023 Heberlein

Heberlein AG, Wattwil, Switzerland, October 26, 2023 – Heberlein, the leading supplier of air interlacing and air texturing jets, has also applied its expertise to develop a unique air-saving solution for a smooth and efficient weaving process. The Heberlein WarpJet-KV needs up to 38% less compressed air compared with other jets. First-hand information is available at the upcoming ITMA Asia (Hall 8.1, Stand A43) – and the key details are presented here.

Heberlein offers a unique retrofit to deliver air savings and more

High-speed weaving and warp knitting processes demand yarns with smooth surfaces for efficient processing. Special procedures to achieve the required yarn quality include air interlacing and sizing. With sustainability in mind sizing is less favoured, since the sizing agent has to be removed after weaving using water and creating high pollution loads.

The art of air interlacing

To develop a novel interlacing system, Karl Mayer, the leading manufacturer of preparation systems for warp knitting and weaving, turned to Heberlein. As a reputable name in filament yarn processes, Heberlein’s competencies in air jets made it an ideal partner. Their collaboration in 2015 started to innovate a completely new air interlacing system that gives considerable economic advantages in warp preparation and the subsequent fabric production sequences.

A process creating reliable intermingling points has several benefits, as the weaving machine no longer stops through shedding issues with filament openings or friction from broken filaments. So, the weaving process runs at higher speeds, also enabling size application to be reduced.

Heberlein’s high-precision components can be used when the process needs maximum efficiency and yarn strength. The WarpJet-KV can increase the intermingling points to 60 to 90 per metre – about triple the usual number, to suit individual requirements in the weaving process. Common speeds from 4,500 to 5,000 m/min in the spinning process usually allow 15/30 nips per metre, which might be sufficient for a smooth weaving process. However, many mills prefer to be on the safe side, especially when using yarns of ? 75 denier and DPF ? 1.0 – so they opt to install the Heberlein intermingling device.

Less air, more profit

The other key aspect is the air pressure needed to guarantee an increased number of intermingling points to assure filament cohesion, especially with fine yarns. During air interlacing, an air blast physically intermingles the individual filaments of a multi-filament yarn with one another.

Saving compressed air in the air interlacing process results in less energy costs. This is proven with the Heberlein WarpJet-KV. Tests at the same machine with 1,536 threads – and using the same level of air pressure – show that compared with a standard jet the WarpJet-KV allows savings of 307 and 491 m3/h. Comparing the air pressure needed for the same amount of intermingling points (FP/m) the savings add up to 38%. Thanks to advanced technology by Heberlein, the diameter of the jet’s air orifice is smaller and requires less air while producing the same number of knots.

Never too early for profitable investment

In warp knitting, the demands are stringent and complex. Uncompromised yarn quality with highest production efficiency at lowest cost – with the premise of sustainable production – is fundamental. That makes it an ideal time for a retrofit with a proven solution: the Heberlein WarpJet-KV. The figures show interlacing performance up to 10 to 30% higher than competitor jets, based on the same air consumption and stability requirement of intermingling points. Air consumption can be 13 to 40% lower for the same number of intermingling points.

Karl Mayer machines can be retrofitted to install Heberlein’s WarpJet-KV with a modification of the main air connection. The modular design of the jets allows up to 64 yarns to be interlaced in a single unit. Depending on the application, customers benefit from the easy exchange of the JetPack and – typically with Heberlein jets – maintenance, cleaning and replacement are easy.

Jets developed for filament perfection

Heberlein Technology AG, Wattwil, Switzerland, October 2, 2025 – Heberlein, the leading supplier of air interlacing and air texturing jets, aims to impress visitors at ITMA Asia + CITME 2025. Novel solutions will be presented, which will allow filament yarn producers to achieve special quality specifications and process optimization. As expected from Heberlein, these latest developments combine the most sophisticated technology with user convenience and savings potential.

It’s the know-how that counts

The Textile Technology Centre is the pride of Heberlein. State-of-the-art equipment and a team of top experts guarantee the highest standards of support for customers. Heberlein is the leading provider of air interlacing and air texturing jets for synthetic continuous filament yarns and its clients enjoy added value in the form of practical help and guidance on textile processes and economic issues, with a special focus on filament yarn applications. This article provides insights into these comprehensive services.

A dynasty of innovators across 190 years

The art of reorientation runs through Heberlein's 190-year company history. Georg Philipp Heberlein and his descendants ran an exemplary family business with roots in yarn dyeing. It developed into a corporate group and ultimately became a highly specialised company that is regarded as the world’s leading provider of air interlacing and air texturing jets for synthetic continuous filament yarns.

DTY Jet insert APe043 redefines low denier yarn processing

Heberlein Technology, a leader in air interlacing and texturing jets, is set to showcase its latest products at GTTES in Mumbai, India. Key highlights include the new housing generation HemaJet-LB06 and the DTY jet insert APe043, featuring a record-small 0.65 mm orifice for superior performance in extremely low denier yarns.

More safety and comfort for protective clothing thanks to auxetic fabrics

When everyday materials are pulled, they stretch or elongate in the direction of the pull and become narrower in cross-section. We can also observe this property in two-dimensional textiles. Auxetic structures behave differently here. They have the striking property of not changing under tensile stress or even increasing their width or thickness. These properties are advantageous, for example, in protective textiles or textile filter media. The DITF are researching auxetic fabrics for various applications.

Perfect quality through collaboration: Machinery from Trützschler, Toyota and Murata at Zirve Tekstil

In today’s textile industry, excellence is not achieved by chance – it’s the result of deliberate decisions, technical expertise, and the courage to go beyond conventional paths. The Turkish company Zirve Tekstil has done just that: by combining the best technologies from Trützschler, Toyota and Murata, they’ve created a production setup that delivers outstanding yarn quality – recognized worldwide.

Engineering depth and diversity for composites

Airbond is the latest member of the British Textile Machinery Association (BTMA) to receive recognition for contributions to the composites industry. The engineering firm based in Pontypool, South Wales, has just received the Make UK Energy and Sustainability Award for its Lattice 3D Printing project.

Award-winning research for sustainable carbon fibre cycles

Sustainable recycling of carbon fibres is possible through targeted electrochemical surface modification, which makes the sizing of carbon fibres resistant to solvolysis. ITA PhD student Sabina Dann was awarded the MSW Award from RWTH Aachen University for her master's thesis on this development. The award ceremony took place on 12 November 2025 in Aachen.